Method of Making Sandwich-Like Product Starting With Extruded Profile

ABSTRACT

A process of making a multi-layered product from an extruded sheet or web of material ( 42 ) having parallel upper and lower walls ( 130 ) and a plurality of spacers ( 134 ) extending between the upper and lower walls ( 130 ) is provided. Portions of the extruded web or extrudate ( 42 ) are removed in selected areas. The lightened web is then folded. Outer skins are then applied to the folded web. The extrudate ( 42 ) is formed into a product ( 10 ) having a plurality of cells ( 14 ). The cells ( 14 ) may have one or more openings ( 34 ), allowing access to an interior of the cell ( 14 ) and reducing the weight of the product ( 10 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 14/179,168 filed Feb. 12, 2014 entitled “Method of Making Core for Sandwich-Like Product Starting with Extruded Profile”, fully incorporated by reference herein. U.S. patent application Ser. No. 14/179,168 is a continuation of U.S. patent application Ser. No. 13/345,166 filed Jan. 6, 2012 entitled “Method of Making Core for Sandwich-Like Product Starting with Extruded Profile”, now U.S. Pat. No. 8,668,855, fully incorporated by reference herein. U.S. patent application Ser. No. 13/345,166 is a continuation-in-part of U.S. patent application Ser. No. 11/566,973 filed Dec. 5, 2006 entitled “Folded Product Made From Extruded Profile and Method of Making Same”, now abandoned, fully incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates generally to a sandwich-like product for structural, packaging and other applications and the process of making the product.

BACKGROUND OF THE INVENTION

In the aerospace industry, honeycomb products have been used as a core component for sandwich panels and boards that are resistant to buckling and bending. These honeycomb products each comprise a plurality of cells, which in cross-section have a generally hexagonal shape. Such products may be fabricated from aluminum, fiber paper or plastic, among other materials. A sandwich structure may be prepared having two cover layers or skins which are welded, adhesively bonded or otherwise secured to the honeycomb product to create a multi-layered or multi-laminate material. Interest expressed in other industrial sectors concerning the use of lightweight sandwich structures is continually growing, due at least in part to the realization of its high strength properties while maintaining a relatively low structural weight-per-volume of product.

A multi-layered or multi-laminate material having a honeycomb product as the core thereof may be used in the packaging industry. However, in automobile part packaging and comparable markets, such a product must compete with corrugated paperboard or corrugated plastic or like materials which may be produced quickly and relatively inexpensively.

U.S. Pat. No. 6,183,836 discloses a honeycomb core for use in a sandwich material in which the material of the honeycomb core is cut and then folded to create a plurality of hexagonal cells. Due to the cuts in the sheet prior to folding the sheet, the resultant cells may be weaker than desired.

A process for producing a folded honeycomb core for use in sandwich materials from a continuous uncut web is disclosed in U.S. Pat. No. 6,726,974. U.S. Pat. No. 6,800,351 discloses another process for producing a folded honeycomb core which includes scoring a corrugated material before rotating interconnected corrugated strips. The honeycomb core resulting from using either of these methods may have material which adds to the weight of the honeycomb core, but may not significantly improve the strength of the honeycomb core.

Accordingly, there is a need for a product which may be used alone or in a multi-layered material, and which has a favorable strength-to-weight ratio.

There is further a need for a process for manufacturing a product, such as a core for use alone or in a multi-layered material, which is less expensive and may be produced in higher quantities than heretofore known processes.

SUMMARY OF THE INVENTION

These and other objectives of the invention have been attained in a process for producing a core for use alone or in a sandwich-like product. The process includes moving an extruded web of material which has spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls. The spacers are spaced from each other, which in combination with the upper and lower walls, define a plurality of flutes.

The process further comprises stopping the movement of the extruded web and treating the web. Treating the web comprises removing portions of the web while the web is stopped with at least one movable tool. In one process, two rotating tools pass across the stopped web, one on each side of the web. The rotating tools may be dado blades or any other known tool such as a milling tool. After selected portions of the extruded web are removed, the web is referred to as a lightened web in this document.

After the treatment is completed, movement of the web resumes without any treatment occurring. The result is a block of untreated material. After a predetermined period of non-treatment passes, the web is stopped and treatment resumed. This process of treating during stoppage of the web, movement without treatment of the web continues.

The process further comprises folding the lightened web such that the flutes of untreated portions or regions of the lightened web become cells of a middle core of a multi-layered product. The flutes go from being generally oriented in a first direction before the lightened web is folded to being generally oriented in a second direction, the second direction being generally perpendicular to the first direction.

The process may further comprise applying outer skins to the cells of the middle core to a multi-layered web or product.

According to another aspect of this invention, a process of making a sandwich-like product comprises providing an extruded web of material having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls. The spacers are spaced from each other to define a plurality of flutes.

The process further comprises removing portions of the extruded web using multiple movable tools to create a treated web having lightened areas transversely extending from one side edge of the extruded web to the other side edge of the extruded web. The movable tools may be rotatable dado blades which travel together in the same direction or travel in opposite directions.

The process further comprises folding the treated web such that upper and lower walls of the untreated regions of the treated web become sidewalls of a plurality of cells arranged in rows of a core of the sandwich-like product. During this folding step, adjacent blocks of untreated material are moved together so they contact each other and are parallel.

The process further comprises applying outer skins to tops and bottoms of the cells of the core to create a multi-layered web.

During any of the processes described or shown herein, a plurality of openings may be introduced into the extruded or lightened web. These openings can be introduced by stamping the material, but may also include processing of the extruded web by one or more tools to thereby form the openings. As used herein, an opening is intended to encompass the situation in which material is removed from the web. The openings may be circular, but may assume one of any number of other shapes, such as oval, hourglass, asymmetric, and the like. The process of removing selected areas of the extruded web may comprise contacting the extruded web with an element which may be heated. Selected areas of the extruded web can be removed by a tool at any desired temperature applying pressure, heat, or a combination of pressure and heat, in one or more selected areas. The process of removing material may precede the introduction of openings into the extruded web, may follow the introduction of openings into the extruded web, or the two processes may occur substantially simultaneously.

According to another aspect of the invention, a process of making a multi-layered or sandwich-like product comprises removing rectangular-shaped portions from an extruded web. The result is alternating treated and untreated rectangular areas in a lightened web, the extruded web having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes.

Another step in the process comprises folding the lightened web such that untreated regions of the extruded web become blocks. Each of the blocks comprises a plurality of cells arranged in a row. The method further comprises joining adjacent blocks to each other to create a middle core and applying outer skins to the middle core.

Regardless of the method used to create the core product, one advantage is that a lightweight, strong product may be quickly and easily manufactured in a desired size or height. The product of this invention, which is produced according to the processes described herein, has a good strength-to-weight ratio even without forming openings in the web, and may be made from many different materials quickly and inexpensively. The strength-to-weight ratio may be improved by strategic removal of material from the extruded web at some time in the process. The product may be used alone, incorporated into a multi-layered sandwich-like material, or used in any other desired manner.

BRIEF DESCRIPTION OF THE DRAWINGS

The objectives and features of the present invention will become more readily apparent when the following detailed description of the drawings is taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a web of material having a generally non-planar, cross-section being extruded from an extruder;

FIG. 1A is a perspective view of a web of material having a generally non-linear, cross-section being extruded from an extruder head of alternate design;

FIG. 1B is a perspective view of a web of material having a generally non-linear, cross-section being extruded from an extruder head of alternate design;

FIG. 1C is a perspective view of a web of material having a generally non-linear cross-section being extruded from an extruder head of alternate design;

FIG. 2 is a perspective view of a portion of the extruded web of FIG. 1;

FIG. 2A is a perspective view of a portion of the extruded web of FIG. 1A;

FIG. 2B is a perspective view of a portion of the extruded web of material extruded from the extruder head of FIG. 1B;

FIG. 2C is a perspective view of a portion of the extruded web of material extruded from the extruder head of FIG. 1C;

FIG. 3 is a perspective view of a portion of the extruded web of FIG. 2 being treated to create transversely extending flats;

FIG. 3A is a side elevational view of a portion of the extruded web of FIG. 1A being treated to create transversely extending flats;

FIG. 3B is an end view of the extruded web of FIG. 2B;

FIG. 3C is an end view of the extruded web of FIG. 2C;

FIG. 4 is a perspective view of a portion of the plastically deformed web of FIG. 3 being folded to create rows of cells;

FIG. 4A is a side elevational view of the web of FIG. 3A being folded to create re-oriented portions containing channels;

FIG. 4B is a perspective view of a portion of the extruded web of FIG. 2B being treated to create a plurality of plastically deformed areas or regions;

FIG. 5 is a perspective view of a portion of the plastically deformed web of FIG. 3 being further folded to create a portion of a honeycomb product;

FIG. 5A is a side elevational view of the web of FIG. 4A after orientation to create a portion of a honeycomb product;

FIG. 5B is a perspective view of a portion of the plastically deformed web of FIG. 4B being folded to create rows of cells;

FIG. 6 is a perspective view of a row of cells;

FIG. 6B is a perspective view of a portion of the extruded web of FIGS. 1B-5B being folded to create a portion of a product;

FIG. 7 is a perspective view of a portion of the plastically deformed web of FIG. 4 being treated to create a plurality of openings in the plastically deformed web;

FIG. 7B is a perspective view of a portion of the extruded web of FIG. 2B being treated to create a plurality of plastically deformed areas or regions in the form of flats;

FIG. 8 is a perspective view of a portion of the plastically deformed web of FIG. 7 being further folded to create rows of cells;

FIG. 8B is a perspective view of a portion of the plastically deformed web of FIG. 7B being folded to create rows of cells;

FIG. 9 is a perspective view of an extruded web having been plastically deformed and punched simultaneously according to another aspect of this invention;

FIG. 10 is a perspective view of a portion of the plastically deformed web of FIG. 9 being folded to create rows of cells;

FIG. 11 is a perspective view of a web of material having a generally non-linear cross-section being extruded from an extruder head of alternate design;

FIG. 11A is an enlarged view of the extruder head of FIG. 11;

FIG. 12 is a perspective view of a portion of an extruded web made with the extruder head of FIG. 11;

FIG. 13 is a cross-sectional view taken along the line 13-13 of FIG. 12;

FIG. 13A is a cross-sectional view of an alternative extrusion;

FIG. 13B is a cross-sectional view of a core made from the extrusion of FIG. 13A;

FIG. 13C is a cross-sectional view of an alternative extrusion;

FIG. 13D is a cross-sectional view of a core made from the extrusion of FIG. 13C;

FIG. 13E is a cross-sectional view of an alternative extrusion;

FIG. 13F is a cross-sectional view of a core made from the extrusion of FIG. 13E;

FIG. 13G is a cross-sectional view of an alternative extrusion;

FIG. 13H is a cross-sectional view of a core made from the extrusion of FIG. 13G;

FIG. 14 is a perspective view of a portion of the extruded web of FIG. 12 being treated to create transversely extending flats;

FIG. 15 is a perspective view of a portion of the treated web of FIG. 14 being folded to create rows of cells;

FIG. 16 is a perspective view of a portion of the treated web of FIG. 14 being further folded to create a portion of a core product;

FIG. 17 is a perspective view of a finished core product;

FIG. 18 is a cross-sectional view taken along the line 18-18 of FIG. 17;

FIG. 19 is an enlarged view of a portion of the treated and folded web of FIG. 16;

FIG. 20 is a perspective view of a portion of the treated web of FIG. 14 being treated to create a plurality of openings in the web;

FIG. 21 is an enlarged view of another extruder head;

FIG. 22 is a perspective view of a portion of an extruded web made with the extruder head of FIG. 21;

FIG. 23 is a cross-sectional view taken along the line 23-23 of FIG. 22;

FIG. 24 is a perspective view of a finished core product;

FIG. 25 is a cross-sectional view taken along the line 25-25 of FIG. 24;

FIG. 26A is a perspective view of a portion of the extruded web of FIG. 2B being treated to create a plurality of shallow areas or regions;

FIG. 26B is a perspective view illustrating a continuation of the process of treating the extruded web shown in FIG. 26A;

FIG. 27A is a perspective view of a portion of the extruded web of FIG. 2B being treated according to another process to create a plurality of shallow areas or regions;

FIG. 27B is a perspective view illustrating a continuation of the process of treating the extruded web shown in FIG. 27A;

FIG. 28 is a perspective view of the extruded web of FIG. 26B or 27B being heating before being folded;

FIG. 29 is a perspective view illustrating a continuation of the process of folding the treated web shown in FIG. 28;

FIG. 30 is a perspective view of outer skins being applied to the treated and folded web of FIG. 29;

FIG. 31 is a perspective view of the multi-layered web of FIG. 30 being cut to create a finished sandwich-like product; and

FIG. 32 is a perspective view of a core web being cut and outer skins being applied to the cut core to create a finished sandwich-like product.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 5, a portion of a honeycomb product 10, according to one embodiment of this invention, is shown. The honeycomb product 10 may be made using numerous processes, including those described herein and others within the scope of the claims. FIG. 5 shows a portion of a honeycomb product 10 comprising a plurality of rows 12 of identical cells 14 made from extruded web or sheet of material. FIG. 6 illustrates one such row 12 of cells 14. Referring to FIG. 5, the honeycomb product 10 has a generally planar upper surface 16 in a generally horizontal plane P1 and a generally planar lower surface 18 in a generally horizontal plane P2, the distance between which defines the height H of the honeycomb product 10. The height H of the honeycomb product 10 may be any desired distance and is not intended to be limited to the height of the illustrated portion of the honeycomb product.

As shown in FIGS. 4 and 5, each row 12 of cells 14 is made by bringing two adjacent hinged row walls 20 together in an accordion-like manner. Each row wall 20 has alternating planar and non-planar regions or areas 22, 24, respectively. Each non-planar region 24 in FIGS. 4 and 5 comprises three rectangular walls comprising a half-hexagon in cross-section. Regions 24 are bounded by planar regions 22. During the process of making the honeycomb product 10, adjacent row walls 20 are brought together so that the planar regions 22 of adjacent row walls 20 at least partially contact each other and the non-planar regions 24 of row walls 20 define sides or side walls 74, 76 of cells 14.

In certain applications, such as, for example, when a web of thermoplastic material is heated at some stage in the manufacture of the honeycomb product 10, the planar regions 22 of adjacent row walls 20 may be bonded, welded or secured to each other without any additional material. Alternatively, adhesive or other bonding agent may be used to secure adjacent row walls 20 together to complete the rows 12 of cells 14. The non-planar regions 24 of adjacent row walls 20 are spaced apart and define the shape or configuration of the cells 14 after the manufacturing process has been completed. Outermost portions or sides 74 of adjacent cells 14 in different rows 12 may contact each other and may be secured to each other in certain applications of this invention.

Although the drawings illustrate each non-planar region 24 of each row wall 20 having a cross-sectional configuration of a half-hexagon, the non-planar regions of the row walls may have any desired cross-sectional configuration, such as, for example, a curved or arcuate or sinuous cross-sectional configuration. The creation of the side walls or sides 74, 76 of the cells 14 is described in more detail below. Depending upon the application, the cells 14 may be any desired shape or size.

As best illustrated in FIG. 6, each cell 14 has a top 28 and a bottom 30 of a predetermined size and/or shape. As shown in FIG. 5, the tops 28 of the cells 14 are located in plane P1 and make up part of the upper surface 16 of the honeycomb product 10. Likewise, the bottoms 30 of the cells 14 are located in plane P2 and make up part of the lower surface 18 of the honeycomb product 10. The top 28, bottom 30 and sides 72, 74 of the cell 14 define a cell interior 32.

In the illustrated embodiment, each cell top 28 and bottom 30 is a polygon and, more particularly, a hexagon. However, if the non-planar regions of the row walls were in the shape of half a cylinder, then the tops and bottoms of the cells would be circular or oval and the cells would have a cylindrical interior.

FIGS. 1-4 illustrate a method or process of making a honeycomb product 10 which may be used alone, in a multi-layered material or product, or in any desired manner. FIG. 1 illustrates an extruder 40 extruding a web of material 42, which is shown in more detail in FIG. 2. Although one configuration of extruder 40 and extruder head 41 is illustrated, any type or configuration of extruder known in the art may be used. The extruder and extruder head configurations will vary as a function of the material being extruded and the cross-section of the extrudate. The material can include any of a variety of plastic compositions and any other material capable of being extruded, and can encompass additional compositions which can be further processed to produce a honeycomb product.

In FIG. 2, the extruded web 42 travels in a direction indicated by arrow 43. The extrudate 42 has a pair of opposed side edges 45, the linear distance between which defines the width or transverse dimension of the extruded web 42. The extruded web 42 may be any desired material of any desired thickness and/or width.

The extruded web 42 has a generally non-linear, cross-section or cross-sectional configuration. In cross-section, the extruded web 42 has a generally corrugated configuration or shape, including a plurality of flattened peaks 48 and a plurality of flattened valleys 50 joined together by connecting portions 52. Each of the flattened peaks 48, flattened valleys 50 and connecting portions 52 are longitudinally extending as shown in FIG. 2. The flattened valleys 50 are all generally co-planar in a horizontal plane P3. Likewise, the flattened peaks 48 are all generally co-planar in a horizontal plane P4 above the plane P3. The linear distance between the planes P3 and P4 defines the height H1 of the corrugations 46. Although one shape or configuration of extruded web 42 is illustrated in FIG. 2, the extruded web 42 may assume numerous other non-linear configurations in cross-section. For example, the expanded view of the extruder head in FIG. 1A shows an alternate cross-sectional shape which can be used to create the non-linear, cross-section extruded web. A perspective view of the extruded web 42′ formed by the alternate extruder head design is provided in FIG. 2A.

FIGS. 3 and 4 illustrate a step in this process of making honeycomb product 10 comprising plastically deforming or flattening at least selected portions or areas 54, 56 of the extruded web 42 to create a plastically deformed extruded web 58. This plastic deformation may include using movable tools 60, 61, such as shown in FIG. 3 to interrupt the continuous corrugations 46 formed in the emerging extruded web 42 and create a plurality of corrugated regions or areas 62, each comprising a plurality of corrugations 46 extending in a first direction generally parallel the direction of travel 43 of the extruded web 42 or longitudinally, and a plurality of flats or flattened areas 54, 56 each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 62, 54 and 56 may vary depending upon the desired size or shape of the cells 14 of the honeycomb product 10.

Although tool 60 is illustrated as comprising three bars 64 joined together with connectors 66 (only one being shown for clarity), and tool 61 is illustrated as comprising two bars 64 joined together with connectors 65 (only one being shown for clarity), respectively, these tools 60, 61 may comprise any number of bars of any desired size or configuration joined together or not. Although two tools are illustrated, any number of tools of any desired type or configuration may be used. Again, the term tool is not intended to be limiting and may include any tool known in the art.

During the step of plastically deforming at least selected portions of the extruded web 42, the bars 64 of the tools 60, 61 may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 38. This heating step is optional and may be used in certain applications only. In other applications, it may be omitted partially or entirely. Although it is shown schematically after the flats 54, 56 have been created in the extruded web 42, this heating step may occur any time during this manufacturing process.

Due to the creation of the flattened areas or flats 54, 56, each corrugation 46 may have an end portion 69 which extends between a peak 48 and a valley 50. These end portions 69 are illustrated as each being in the shape of a trapezoid, but may be other shapes, depending upon the shape of the corrugations.

As best illustrated in FIGS. 3 and 4, each generally rectangular, transversely extending flat or flattened area 56 is located in the plane P3 of the extruded web 42. Each generally rectangular, transversely extending flat or flattened area 54 is located in plane P4 above the plane P3 of the extruded web 42 and co-planar with the plane of the flattened peaks 48 of corrugations 46. Flattened areas 56 and 54 alternate between corrugated regions 62. As seen in FIG. 4, due to the shape of the tools 60, 61, each flat or flattened area 54 has side walls 70 extending from the outer edges of the flat 54 to the flattened valleys 50 in the corrugated regions 62. These side walls 70 are illustrated as each being in the shape of a trapezoid, but may be other shapes, depending upon the shape of the corrugations. Although not shown, the corrugations may have a semi-circular, sinuous, curved or other cross sectional configuration.

As shown in FIG. 4, the plastically deformed web portion 58 is then folded along transversely extending fold lines 72 located generally on the edges of the flats 54, 56. Such fold lines 72 may be optionally scored or perforated at any step in the manufacturing process with cuts 71 to assist folding. Such scoring may be made by a separate tool or tools. As shown in FIG. 5, after the plastically deformed web portion 58 is folded along transversely extending fold lines 72, side walls 70 lay underneath and may contact the raised flat 54, and end walls 69 of corrugations 46 rest on and contact flats 56.

As best illustrated in FIG. 6, side walls 70 abut and are underneath portions of the raised flats 54. These two-ply areas comprise approximately half of the tops 28 of some of the cells 14. In such cells, the bottom 30 of the cell 14 is a single-ply which was formed in the flat 56 before folding. As shown in FIG. 6, end walls 69 abut and are above portions of the flats 56 to form approximately half of the bottoms 30 of other cells 14. In such cells, the top 28 of the cell 14 is a single-ply which was formed in the flat 54 prior to folding. Thus, in one row 12 of cells 14, each cell 14 has a single-ply top 28 and a double-ply bottom 30. In adjacent rows of cells 14, each cell 14 has a double-ply top 28 and a single-ply bottom 30.

As shown in FIGS. 4, 5 and 6, after the plastically deformed web portion 58 is folded along transversely extending fold lines 72, the corrugations 46 or non-planar regions 24 of the row walls 20 become the side walls 74, 76 of the cells 14. More particularly, the generally planar peaks 48 of corrugations 46 shown in FIG. 4 become the outmost side walls 74 of the cells 14, and the generally planar connecting portions 52 of corrugations 46 become additional side walls 76 of the cells 14. As shown in FIGS. 5 and 6, within a row 12 of cells 14, the planar portions 22 of row walls 20 come together to create flattened two-ply portions 77 of row 12. Side walls 74, 76, along with the top 28 and bottom 30 of each cell 14, define a cell interior 32.

The last step in the process is to cut the extruded web 42 at any desired location. FIG. 4 illustrates a cutter 78 at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10 of a desired length.

FIGS. 7-8 illustrate another method or process of making a honeycomb product which may be used alone or in a multi-layered material or product. FIG. 7 illustrates an extruded web 42 a traveling in a direction indicated by arrow 43 a and having a pair of opposed side edges 45 a, the linear distance between which defines the width or transverse dimension of the extruded web 42 a. The extruded web 42 a may be any desired material of any desired thickness and/or width. The extruded web 42 a is identical to extruded web 42 described above.

The extruded web 42 a is then treated as described above and illustrated in FIG. 3 to create a plastically deformed web portion 58 a having a plurality of corrugations 46 a. As seen in FIG. 7, the corrugations 46 a may comprise co-planar flattened peaks 54 a in a plane P6 and flattened valleys 56 a in the plane P5 of the extruded web 42 a with generally rectangular flat connecting portions 52 a extending therebetween. Lastly, each corrugation 46 a may have an end portion 69 a. These end portions 69 a are illustrated as each being in the shape of a trapezoid, but may be other shapes, depending upon the shape of the corrugations.

As best illustrated in FIG. 7, each generally rectangular, transversely extending flat or flattened area 56 a is located in the plane P5 of the extruded web 42 a. Therefore, each generally rectangular, transversely extending flat or flattened area 54 a is located in plane P6 above the plane P5 of the extruded web 42 a and co-planar with the flattened peaks 48 of corrugations 46 a. Flattened areas 56 a and 54 a alternate between corrugated areas 62 a. Each flat 54 a has side walls 70 a extending from the outer edges of the flat 54 a to the flattened valleys 50 a in the corrugated regions 62 a. These side walls 70 a are illustrated as each being in the shape of a trapezoid, but may be other shapes, depending upon the shape of the corrugations. Although not shown, the corrugations may have a semi-circular, sinuous, curved or other cross sectional configuration.

FIG. 7 illustrates a movable tool 82 in the form of a punch press which is used to remove material 84 from plastically deformed web 58 a in predetermined or preselected locations. In FIG. 7, the punch press or tool 82 has a plurality of punchers 86 mounted on a plate 88 at preselected or predetermined locations or positions to create a plurality of rectangular openings 34 a through predetermined or preselected portions of the plastically deformed web 58 a. These openings 34 a become the openings in the honeycomb product 10 a described above. See FIG. 8. Although illustrated as being rectangular, the openings 34 a may be of any predefined desired size or shape and strategically located at any desired location on a portion of unrolled web. For example, the holes or openings 34 a may be circular and be oriented such that each cell 14 has at least one opening 34 a allowing access to the interior of the cell 14.

Although a punch press is illustrated, any other tool, such as a laser cutter, may be used to create the openings 34 a through any portion of the plastically deformed portion 58 a of the extruded web 42 a to lighten the extruded web 42 a so that when this portion of the web 42 a is formed into a honeycomb product 10 a, the resultant honeycomb product 10 a has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the honeycomb product.

Although the tool 82 is illustrated beneath the extruded web 42 a, tool 82 may be located above the extruded web 42 a or at any desired location. More than one tool may be used if desired.

As shown in FIGS. 7-8, the strategic locations of the openings 34 a are such that the openings 34 a are located along the flats 54 a, 56 a of the plastically deformed web 58 a, along the flattened peaks 48 a of the corrugations 46 a and along connecting portions 52 a of corrugations 46 a. As shown in FIG. 7, each opening 34 a is illustrated as being generally rectangular, but may be any predefined or preselected shape or size. As shown in FIGS. 7 and 8, some of the holes 34 a in flats 54 a, 56 a extend through the bottoms 30 a and tops 28 a of cells 14 a. Likewise, holes 34 a through the connecting portions 52 a of the corrugations 62 a extend through the side walls 76 a of cells 14 a.

As shown in FIG. 7, after the openings 34 a have been bored, punched or otherwise made, the plastically deformed web portion 58 a is then folded along transversely extending fold lines 72 a located generally on the edges of the flats 54 a, 56 a. As shown in FIGS. 7 and 8, after the plastically deformed web 58 a is folded along transversely extending fold lines 72 a, side walls 70 a lay underneath the raised flats 54 a and end walls 69 a of corrugations 62 a rest on flats 56 a.

The last step in the process is to cut the extruded web 42 a at any desired location. FIG. 7 illustrates a cutter 78 a at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10 a of a desired length.

FIG. 8 shows a portion of the resultant honeycomb product 10 a along with skins or layers 80 (shown in phantom), one or both of which may be secured to at least one of the upper and lower surfaces 16 a, 18 a of honeycomb product 10 a to create a multi-layered product for any desired use. Such skins may be incorporated into a product having a honeycomb core or product made in accordance with any aspect of the present invention, including via any method described or contemplated herein.

FIGS. 9-10 illustrate another method or process of making a honeycomb product 10 b which may be used alone or in a multi-layered material or product.

FIGS. 9 and 10 illustrate another method or process of making a honeycomb product 10 b which may be used alone or in a multi-layered material or product, comprising plastically deforming at least portions of the extruded web 42 b. Plastic deformation may include using movable tools 60 b, 61 b, such as shown in FIG. 9 to create a plurality of corrugated regions or areas 62 b comprising a plurality of corrugations 46 b extending in a first direction generally parallel the direction of travel 43 b of the web 42 b or longitudinally, and a plurality of flattened areas or regions 54 b, 56 b, each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 62 b, 54 b and 56 b may vary depending upon the desired size or shape of the cells 14 b of the honeycomb product 10 b. See FIG. 10.

FIG. 9 illustrates movable tools 60 b, 61 b, which, in addition to plastically deforming the extruded web 42 b, also remove material 84 b from plastically deformed web 58 b in predetermined or preselected locations. In FIG. 9, each of the tools 60 b, 61 b has a plurality of punchers 86 b mounted on bars 64 b at preselected or predetermined locations or positions to create a plurality of circular openings 34 b through predetermined or preselected portions of the plastically deformed web 58 b. These openings 34 b become the openings in the honeycomb product 10 b described above. Although illustrated as circular, the openings 34 b may be of any desired shape and strategically located at any desired location on a portion of the extruded web.

Although one configuration of tool 60 b (and 61 b) is illustrated comprising bars 64 b joined by connectors 66 b (and 65 b), any other configuration or type of tool may be used to plastically deform extruded portions of web 42 b. Such tools may simultaneously create openings 34 b through any portion of the extruded web to lighten the extruded web 42 b so that when this portion of the web 42 b is folded to create honeycomb product 10 b, the resultant honeycomb product 10 b has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the honeycomb product 10 b.

Although the tools 60 b and 61 b are illustrated respectively above and below extruded web 42 b, the orientation of tools 60 b and 61 b may be reversed, or at any other desired location, such as one after the other in a staggered format. Any number of tools 60 b, 61 b may be used if desired.

During the step of plastically deforming at least selected portions of the extruded web 42 b, the bars 64 b of the tools 60 b, 61 b may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 38 b. This heating step is optional and may be used in certain applications only. In other applications, it may be omitted partially or entirely. This heating step may occur any time during this manufacturing process.

As shown in FIG. 10, after the web 42 b has been plastically deformed and the openings 34 b have been created, the plastically deformed web portion 58 b is then folded along transversely extending fold lines 72 b located generally on the edges of the flats 54 b, 56 b. As shown in FIGS. 9 and 10, after the plastically deformed web of material 58 b is folded along transversely extending fold lines 72 b, side walls 70 b lay underneath the raised flats 54 b and end walls 62 b of corrugations 60 b rest on flats 56 b.

The last step in the process is to cut the plastically deformed extruded web 58 b at any desired location. FIG. 10 illustrates a cutter 78 b at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10 b of a desired length.

As noted above, the cross-section of the extruded web can assume any number of shapes. FIGS. 1A-5A illustrates an alternative method of producing a honeycomb product and the product made by that method.

The temperature needed to process a plasticated material through an extruder and out an extruder head, such as 41′ in FIG. 1A, in conjunction with the properties of the material being extruded, the extruder speed, and complexity of the desired cross-section shape, may create an extruded web 42′ which may retain an unacceptably high internal heat after exiting the extruder head 41′. If not cooled to an acceptable temperature promptly after exiting the extruder head, such an extrudate may warp or show other indicia of degradation due to excessive levels of heat being retained. As shown in FIG. 2A, the channels 44 of the web 42′, though open at one end, may be otherwise effectively closed to transport air or other heat exchange medium. Such channels 44 are described herein as being closed.

To improve access, one or more access openings 101 may be introduced into one or more longitudinally extending channels 44 of the web 42′. Creation of an access opening 101 into a channel forms a modified channel 44′, described herein as being substantially closed. See FIG. 2A. The access opening 101 may be created in the web 42′ by appropriate machining of the extruder head 41′, or by the action of a cutting or material-removing tool (not shown) downstream of the extruder head 41′. Only one access opening 101 is shown in FIG. 2A on only one channel 44, but additional channels 44 can have one or more access openings 101, up to all of the channels in the extrudate. The access opening or openings can vary in size or shape as needed to facilitate transport of sufficient quantities of a heat exchange medium between the interior and exterior of a channel 44. The access opening 101 is depicted as being continuous along the channel 44, but this is not required. Any number of access openings 101 may be any desired length. FIG. 1A depicts an alternate extrusion cross-section shape, as shown in extruder head 41′. FIG. 2A depicts an alternate extruded web 42′ formed by use of extruder head 41′ containing closed corrugations, or channels 44, the channel as depicted having a hexagonal shape in cross-section.

FIGS. 3A-5A depict side elevational views of the process of flattening portions of an extruded web of the general configuration depicted in FIG. 2A having channels therein, followed by folding and re-orienting portions of the extruded web to create a honeycomb structure, portions of the extruded web being re-oriented at 90° relative to their original machine direction orientation or position.

As shown in FIG. 3A, sections 110 of the extruded web 42′ may be flattened by tools 116, alternating the sections 110 being compressed into upper flats 118 and lower flats 120. Tool 116 may apply pressure only, heat only, or a combination of pressure and heat, to create flats 118, 120.

Additional portions 124 a-d shown in FIG. 3A each contain at least one channel disposed horizontally, which may be either closed or substantially closed. At least one portion is capable of being manipulated by a folding operation to mate with an adjacent portion, i.e., 124 a with 124 b, 124 b with 124 c, or 124 c with 124 d, as shown in FIGS. 4A and 5A, to form vertically oriented cells 14′.

FIG. 4A depicts portions 124 a-d in varying degrees of re-orientation, from an original machine direction having closed channels disposed horizontally, to an orientation at 90° relative to the original machine direction, wherein the channels, now cells 14′, are substantially vertical. The portions 124 a-d re-orient along hinge lines 128.

FIG. 5A depicts the portions 124 a-d, along with similarly disposed portions, after folding and re-orientation. The resulting honeycomb product 10′ is comprised in part of re-oriented portions 124 a, 124 b, 124 c, and 124 d, with upper flats 118 and lower flats 120, respectively, disposed above and below selected portions 124 a-124 d, the upper and lower flats being offset relative to each other.

FIG. 1B depicts an extruder 40″ with an alternate extruder head 41″ used to extrude an extrusion 42″ having a non-planar profile and non-linear cross-section, as shown in FIGS. 2B and 3B. FIG. 2B depicts a portion of the extruded web 42″ formed by use of extruder head 41″, the extruded web 42″ having a non-linear, cross-section. For purposes of this document, the portion of extruded web 42″ shown in FIG. 2B has a non-planar profile because it does not comprise a single solid flat sheet of material. The present invention is intended to cover all extrusions which are not solid flat sheets or webs of material.

As seen in FIG. 3B, the extruded web 42″ has spaced upper and lower horizontal walls 130 in planes P7 and P8, the linear distance between these planes defining the height H2 of the extrudate 42″. The extrudate 42″ also has side walls 132, the distance between which defines the width or transverse dimension W2 of the extrudate 42″. Lastly, the extrudate 42″ has a plurality of spacers 134 extending between the horizontal walls 130 and spaced from each other so as to define a plurality of flutes or channels 136 which extend longitudinally or in the direction of travel 43 of the web. As shown in FIG. 3B, these flutes or channels 136 have a rectangular shape in cross-section. As seen in FIG. 2B, the extruded web 42″ travels in a direction indicated by arrow 43. The extruded web 42″ may be any desired material of any desired thickness and/or width. This type of extrusion, if made of plastic, is known as one type of corrugated plastic.

One advantage of the present invention is the ability to extrude a product with reduced weight or density compared to the weight or density of a single solid sheet or web of the same material of the same dimensions. Due to the presence of holes, flutes or channels 136 in the extrudate 42″, as best shown in FIG. 3B, the weight of any length of extrudate 42″ is less than half the weight of a solid piece of material of the same dimensions. The same is also true of the extrudate shown in FIG. 2.

FIGS. 4B and 5B illustrate additional steps in this process of making product 10″. FIG. 4B illustrates the step of plastically deforming at least selected portions or areas 138 of the extruded web 42″ to create a plastically deformed extruded web 58″. This plastic deformation may include using movable tools 140, 142, such as shown in FIG. 4B, to interrupt the continuous corrugations or flutes 136 formed in the emerging extruded web 42″ and create a plurality of generally V-shaped plastically deformed regions or areas 138, each extending generally perpendicular to the direction of travel 43 of the extruded web 42″ or transversely or from side-to-side. The size of these regions or areas 138 may vary depending upon numerous factors, including the desired size or shape of the cells 14 of the resulting product 10″. For purposes of this document, the term “plastically deforming” includes cutting, shaping, expanding or flattening to physically transform the shape of the profile.

Although tool 140 is illustrated as comprising six deforming members 144 joined together with connectors 146 (only one being shown for clarity), and tool 142 is illustrated as comprising five deforming members 148 joined together with connectors 150 (only one being shown for clarity), respectively, these tools 140, 142 may comprise any number of deforming members of any desired size or configuration, joined together or not. Although two movable tools are illustrated, any number of tools of any desired type or configuration may be used. Again, the term tool is not intended to be limiting and may include any tool known in the art. For example, deforming members 144, 148 may be blades used for cutting.

During the step of plastically deforming at least selected portions of the extruded web 42″, the deforming members 144, 148 of tools 140, 142, respectively, may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 152. This heating step is optional and may be used in certain applications only. In other applications, it may be omitted partially or entirely. Although it is shown schematically during the creation of the plastic deformed areas 138 of the extruded web 42″ using tools 140, 142, this heating step may occur any time during this manufacturing process.

As shown in FIGS. 5B and 6B, the plastically deformed web portion 58″ is then folded along transversely extending fold lines 154 located generally in the planes P7 and P8 of the extrudate 42″. See FIG. 3B. Such fold lines 154 may be optionally scored or perforated at any step in the manufacturing process with cuts (not shown) to assist folding. Such scoring may be made by a separate tool or tools. As shown in FIG. 6B, after the plastically deformed web portion 58″ is folded along transversely extending fold lines 154, horizontal walls 130 of extrudate 42″ become vertically orientated, and the flutes 136 become the vertically oriented cells 14″ of the resultant product 10″.

Another step in the process may be to cut the extruded web 42″ at any desired location. FIG. 4B illustrates a cutter 78 at one location. However, one or more cutting tools or devices may be used at any desired location to create a product 10″ of a desired length.

FIG. 6B shows a portion of the resultant product 10″ along with skins or layers 80 (shown in phantom), one or both of which may be secured to at least one of the upper and lower surfaces of product 10″ to create a multi-layered or sandwich-like product for any desired use. As shown in FIG. 6B, the plastically deformed web 58″ is folded alternatively in upper and lower planes P7 and P8 to create a plurality of blocks 137, each block 137 containing a row 139 of vertically oriented cells 14″. If desired, adjacent blocks 137 may be adhesively or otherwise joined to each other to create product 10″, with or without any skins 80.

FIGS. 7B and 8B illustrate another method or process of making a product 160, which may be used alone or in a multi-layered material or product. FIG. 7B illustrates an extruded web 42″ like the one described above and shown in FIGS. 1B, 2B and 3B, traveling in a direction indicated by arrow 43.

This method comprises plastically deforming or flattening at least selected portions or areas 162, 164 of the extruded web 42″ to create a plastically deformed extruded web 166. This plastic deformation may include using movable tools 168, 170, such as shown in FIG. 7B to interrupt the continuous corrugations or flutes 136 formed in the emerging extruded web 42″ and create a plurality of non-deformed regions or areas 172 and a plurality of flats or flattened areas 162, 164, each extending in a second direction perpendicular to the direction of travel of the extruded web, transversely or from side-to-side. The size and location of these regions or areas 162, 164 and 172 may vary depending upon the desired size or shape of the cells 165 of the resultant product 160.

Although tool 168 is illustrated as comprising three bars 174 joined together with connectors 176 (only one being shown for clarity), and tool 170 is illustrated as comprising two bars 174 joined together with connectors 180 (only one being shown for clarity), respectively, these tools 168, 170 may comprise any number of bars of any desired size or configuration joined together or not. Although two tools are illustrated, any number of tools of any desired type or configuration may be used. Again, the term tool is not intended to be limiting and may include any tool known in the art.

During the step of plastically deforming at least selected portions of the extruded web 42″, the bars 174 of the tools 168, 170 may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 178. This heating step is optional and may be used in certain applications only. In other applications, it may be omitted partially or entirely. Although it is shown schematically after the flats 162, 164 have been created in the extruded web 42″, this heating step may occur any time during this manufacturing process.

As best illustrated in FIGS. 7B and 8B, each generally rectangular, transversely extending flat or flattened area 162 is located in the plane P8 of the extruded web 42″. Each generally rectangular, transversely extending flat or flattened area 164 is located in plane P7 above the plane P8 of the extruded web 42″. Flattened areas 162 and 164 alternate between corrugated or non-deformed regions 172. Each corrugated region 172 comprises rows of corrugations.

As shown in FIG. 5B, the plastically deformed web portion 166 is then folded along transversely extending fold lines 154 located generally in the planes P7 and P8 of the extrudate 42″. See FIG. 3B. Such fold lines 154 may be optionally scored or perforated at any step in the manufacturing process with cuts (not shown) to assist folding. Such scoring may be made by a separate tool or tools. As shown in FIG. 6B, after the plastically deformed web portion 166 is folded along transversely extending fold lines 154, horizontal walls 130 of extrudate 42″ become vertically orientated, and the flutes 136 become the cells 14″ of the resultant product 160.

FIG. 8B shows a portion of the resultant product 160 along with skins or layers 80 (shown in phantom), one or both of which may be secured to at least one of the upper and lower surfaces of product 160 to create a multi-layered or sandwich-like product for any desired use. As shown in FIG. 8B, the plastically deformed web 166 is folded alternatively in upper and lower planes P7 and P8 to create a plurality of blocks 161, each block 161 containing a row of vertically oriented cells like the ones shown in FIG. 6B. If desired, adjacent blocks 161 may be adhesively or otherwise joined to each other to create product 160 with or without skins 80.

Another step in the process may be to cut the extruded web 166 at any desired location. FIG. 7B illustrates a cutter 78 at one location. However, one or more cutting tools or devices may be used at any desired location to create a product 160 of a desired length.

FIG. 10 depicts an extruder 40 c with an alternate extruder head 41 c used to extrude an extrusion having a non-planar profile and non-linear, cross-section, as shown in FIGS. 2C and 3C. FIG. 2C depicts a portion of the extruded web 42 c formed by use of extruder head 41 c, the extruded web 42 c having a non-linear, cross-section. FIG. 2C depicts an alternate extruded web 42 c formed by use of extruder head 41 c, the extruded web 42 c having a non-linear, cross-section. As seen in FIG. 3C, the extruded web 42 c has spaced upper and lower horizontal walls 182 in planes P9 and P10, the linear distance between these planes defining the height H3 of the extrudate 42 c. The extrudate 42 c also has side edges 184, the distance between which defines the width or transverse dimension W3 of the extrudate 42 c. Lastly, the extrudate 42 c has a sinuous middle member 186 extending between the horizontal walls 182 so as to define a plurality of flutes or channels 188 which extend longitudinally. As seen in FIG. 2C, the extruded web 42 c travels in a direction indicated by arrow 43. The extruded web 42 c may be any desired material of any desired thickness and/or width. Such an extruded web 42 c may be treated or processed as described above to create a product for use alone or in a sandwich-like core product.

FIGS. 11-19 illustrate a method or process of making a multi-layered or sandwich-like product 200, shown in FIGS. 17 and 18. The product 200 comprises upper and lower generally planar skins 258 secured to a middle core 198. FIG. 11 illustrates an extruder 202 having an extruder head 204 shown in more detail in FIG. 11A.

As best shown in FIG. 11A, the extruder head 204 comprises a movable first or upper piece 206 having a jagged or tooth-shaped lower edge 208 and a movable second or lower piece 210 having a jagged or tooth-shaped upper edge 212. Each piece 206, 210 may be independently movable relative to the other, as shown by arrows 211. A gap 214 between the lower edge 208 of the upper piece 206 and the upper edge 212 of the lower piece 210 defines the size of the extrudate or web of material 216 exiting the extruder head 204. In particular, the distance “D” between the lower edge 208 of the upper piece 206 and the upper edge 212 of the lower piece 210 defines the thickness “T” of the extrudate 216 exiting the extruder head 204. Although one configuration of extruder 202 is illustrated, any type or configuration of extruder known in the art may be used. The extruder and extruder head configurations will vary as a function of the material being extruded and the cross-section of the extrudate. The material can include any of a variety of plastic compositions and any other material capable of being extruded, and can encompass additional compositions which can be further processed to produce a sandwich-like product for packaging or other desired applications.

As shown in FIG. 12, the extruded web 216 travels in a direction indicated by arrow 218. The extruded web 216 has a pair of opposed side edges 220, the linear distance between which defines the width or transverse dimension of the extruded web 216. The extruded web 216 may be any desired material of any desired shape, i.e., thickness and/or width.

The extruded web 216 has a generally non-planar profile or non-linear, cross-section or cross-sectional configuration. In cross-section, the extruded web 216 has a generally corrugated configuration or shape, including a plurality of peaks 222 and a plurality of valleys 224 joined together by connecting portions 226, all extending in the direction of travel of the web shown by arrows 218 during the extrusion process. Each of the peaks 222, valleys 224 and connecting portions 226 are longitudinally extending, as shown in FIG. 12, extending parallel the outer edges 220 of the extruded web 216. The valleys 224 are all generally co-planar in a horizontal plane P₁₁. Likewise, the peaks 222 are all generally co-planar in a horizontal plane P₁₂ above the plane P₁₁. The linear distance between the planes P₁₁ and P₁₂ defines the height “HH” of the corrugations 228. Although one shape or configuration of extruded web 216 is illustrated in FIGS. 12 and 13, the extruded web 216 may assume numerous other non-linear configurations in cross-section, such as those shown in FIGS. 13A, 13C, 13E and 13G.

FIGS. 14 and 15 illustrate part of the process of making the core 198 of the sandwich-like product 200 shown in FIG. 17. This part of the process comprises plastically deforming or flattening at least selected portions or areas 230, 232 of the extruded web 216 to create a plastically deformed or treated extruded web 234 shown being folded in FIG. 15. This plastic deformation may include using movable tools 236, 238, such as those shown in FIG. 14, to interrupt the continuous corrugations 228 formed in the extruded web 216 and create a plurality of corrugated regions or areas 240 between adjacent flattened areas 230, 232. Each corrugated region 240 comprises a plurality of corrugations 228 extending in a first direction generally parallel the direction of travel 218 of the extruded web 162 or longitudinally, and a plurality of flats or flattened areas 230, 232 each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 230, 232 and 240 may vary depending upon the desired size or shape of the cells of the core 198.

Although upper tool 236 is illustrated as comprising three parallel bars 242 joined together with connectors 244 (only one being shown for clarity), and lower tool 238 is illustrated as comprising two bars 243 joined together with connectors 245 (only one being shown for clarity), respectively, these tools may comprise any number of bars of any desired size or configuration joined together with any number of connectors or not. Although two tools are illustrated, any number of tools of any desired type or configuration may be used. Again, the term tool is not intended to be limiting and may include any tool known in the art.

During the step of plastically deforming or flattening at least selected portions 230, 232 of the extruded web 216, the bars 242, 243 of the tools 236, 238 may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 38. This heating step is optional and may be used in desired applications only. In other applications, it may be omitted partially or entirely. Although it is shown schematically after the flats 230, 232 have been created in the extruded web 216, this heating step may occur any time during this manufacturing process.

Due to the creation of the flattened areas or flats 230, 232, each corrugation 228 may have end portions 246, each end portion 246 extending between a peak 222 and a valley 224. These end portions 246 are illustrated as each being in the shape of a triangle, but may be other shapes, depending upon the shape of the corrugations.

As best illustrated in FIGS. 14 and 15, each generally rectangular, transversely extending flat or flattened area 232 is located in the lower plane P₁₁ of the extruded web 216. Each generally rectangular, transversely extending flat or flattened area 230 is located in upper plane P₁₂ above the lower plane P₁₁ of the extruded web 216 and co-planar with the plane of the peaks 222 of corrugations 228. Flattened areas 232 and 230 alternate between corrugated regions 240. In other words, one flat 232 and one flat 230 are on opposite sides of a corrugated region 240.

As shown in FIG. 15, after the extruded web 216 is treated or plastically deformed to create treated extruded web 234, treated extruded web 234 is then folded along transversely extending fold lines 248 located generally on the edges of the flats 230, 232. Such fold lines 248 may be optionally scored or perforated at any step in the manufacturing process with cuts to assist folding. Such scoring may be made by a separate tool or tools.

As shown in FIG. 16, after the plastically deformed web 234 is folded along transversely extending fold lines 248, end portions 246 lie underneath and may contact the raised flat 230, and end portions 246 of corrugations 228 rest on and contact lower flats 232. In other words, as shown in FIG. 19, the triangular portions 250 of the upper horizontal portions 254 of core 198 are two plies thick, the lower ply being the end portions 246 of corrugations 228 before the treated web 234 is folded along fold lines 248. The remainder of the upper flat 230 comprises single-ply diamond-shaped areas 252. The same is true on the lower horizontal portions 256 of core 198.

As shown in FIG. 16, as the treated web 234 is folded along fold lines 248, an upper skin 258 is secured to the upper horizontal portions 254 of core 198, and a lower skin 258 is secured to the lower horizontal portions 256 of core 198. This step may occur separately or simultaneously with the folding step described above. As shown in FIG. 16, the upper horizontal portions 254 of core 198 are located generally in a horizontal plane P₁₃, and the lower horizontal portions 256 of core 198 are located generally in a horizontal plane P₁₄. The linear distance between horizontal planes P₁₃ and P₁₄ comprises the height “H₄” of the core 198.

The last step in the process is to cut the treated web 234 at any desired location. FIG. 16 illustrates a movable cutter 260 at one location. However, one or more cutting tools or devices may be used at any desired location to cut the treated web 234.

As shown in FIG. 18, after the treated web 234 is folded along fold lines 248, the connecting portions 226 of the corrugations 228 of the corrugated regions 240 become side walls 262 of the cells 264 of the core 198. Peaks 222 of the corrugations 228 of one of the corrugated regions 240, shown in FIG. 15, contact peaks 222 of the corrugations 228 of an adjacent corrugated region 240 after the treated web 234 is folded. Similarly, valleys 224 of the corrugations 228 of one of the corrugated regions 240, shown in FIG. 15, contact valleys 224 of the corrugations 228 of an adjacent corrugated region 240 after the treated web 234 is folded.

As shown in FIG. 18, side walls 262, along with the flats 230, 232 of treated web 234, define a cell 264 having a cell interior 266 after the treated web 234 is folded and the skins 258 applied to the upper and lower horizontal portions 254, 256 of the folded web.

FIG. 20 illustrates a movable tool 268 in the form of a punch press which is used to remove material 270 from treated web 234 in predetermined or preselected locations. In FIG. 20, the punch press or tool 268 has a plurality of punchers 272 mounted on a plate 274 at preselected or predetermined locations or positions to create a plurality of openings 276 through predetermined or preselected portions of the treated web 234. These openings 276 become the openings in a core, like the core 198 described above. Although illustrated as being rectangular, the openings 276 may be of any predefined desired size or shape. For example, the openings may be circular or oval-shaped. Similarly, although illustrated as being formed only in the flats 230, 232 of the treated web 234, the openings may be strategically located at any desired location or locations. For example, the openings may be located, such that each cell 264 has at least one opening through the top or bottom of the cell 264, allowing access to the interior 266 of the cell 264.

Although a punch press is illustrated, any other tool, such as a laser cutter, may be used to create openings through any portion of the treated web 234 to lighten the treated web 234 so that when treated web 234 is formed into a core 198, the resultant sandwich-like product 200 has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the core 198.

Although the tool 268 is illustrated beneath the treated web 234, tool 268 may be located above the treated web 234, or at any desired location. More than one tool may be used if desired. The present invention does not intend to limit the tool or tools used to remove material in any of the embodiments described or shown herein.

As shown in FIG. 20, after the openings 276 have been bored, punched or otherwise made, the treated web 234 is then folded, as described above. Although not shown in FIG. 20, any of the extruded webs described or shown herein, including but not limited to extruded web 216, may be treated, such that openings are created therein using any method shown or described herein before being flattened or further treated or after the flats are formed therein.

FIGS. 21-25 illustrate a method or process of making another sandwich-like product having a central core. However, the core of this embodiment is posturized or has regions or areas having different characteristics. The multi-layered or sandwich-like product 300 is shown in FIGS. 24 and 25. The product 300 comprises upper and lower generally planar skins 302 secured to a middle core 304. FIG. 21 illustrates an extruder head 278 which may be used in any convention extruder, including those shown and described herein.

As shown in FIG. 21, the extruder head 278 comprises a movable first or upper piece 280 having a jagged or tooth-shaped lower edge 282, and a movable second or lower piece 284 having a jagged or tooth-shaped upper edge 286. Each piece 280, 284 may be independently movable relative to the other, as shown by arrows 288. A gap 290 between the lower edge 282 of the upper piece 280 and the upper edge 286 of the lower piece 284 defines the size of the extrudate or web of material 292 exiting the gap 290 of extruder head 278. In particular, the distance between the lower edge 282 of the upper piece 280 and the upper edge 286 of the lower piece 284 defines the thickness of the extrudate 292 exiting the extruder head 278. In this embodiment, the thickness of the extrudate 292 is not uniform across the width of the extrudate 292, as shown in FIGS. 22 and 23 due to the configurations of the pieces 280, 284 of the extruder head 278. As shown in FIGS. 22 and 23, the extrudate 292 may be divided into three different regions, two outer regions 294 of a uniform thickness “T₁” and a middle region 296 of a uniform thickness “T₂”, greater than the thickness “T₁” of the outer regions 294. After being flattened in certain areas and folded, the core 304 has the skins 302 applied and cut to size as described herein to create the finished sandwich-like product 300 shown in FIG. 24.

FIG. 25 illustrates a cross-section of the core 304 having a plurality of cells 306, each cell 306 comprising side walls 308, a top 310 and a bottom 312 defining a hollow interior 314. The interior 314 is diamond-shaped in cross-section, as seen in FIG. 25.

FIGS. 13A and 13B illustrate an alternative extrusion 216 a. This extrusion 216 a, shown in cross-section in FIG. 13A, has a generally non-planar profile or non-linear, cross-section. In cross-section, the extruded web 216 a has a generally corrugated configuration or shape, including a plurality of peaks 222 a and a plurality of valleys 224 a joined together by connecting portions 226 a, all extending in the direction of travel of the web during the extrusion process. Each of the peaks 222 a, valleys 224 a and connecting portions 226 a are longitudinally extending, extending parallel the outer edges 220 a of the extruded web 216 a. The valleys 224 a are all generally co-planar in a horizontal plane P₁₅. Likewise, the peaks 222 a are all generally co-planar in a horizontal plane P₁₆ above the plane P₁₅. The linear distance between the planes P₁₅ and P₁₆ defines the height “HH_(a)” of the corrugations 228 a. At the junction of intersecting connecting portions 226 a, i.e., at each peak 222 a and each valley 224 a, additional material at locations 314 is extruded. The additional material may cause the extrudate 216 a to be stronger than if the additional material were omitted.

FIG. 13B illustrates in cross-section a core 198 a made from the extrudate 216 a, shown in FIG. 13A. As shown in FIG. 13B, after the extruded web 216 a is partially flattened and folded along fold lines, the connecting portions 226 a of the corrugations 228 a of the corrugated regions become side walls 262 a of the cells 264 a of the core 198 a. More particularly, the peaks 226 a of the corrugations 228 a of the corrugated regions shown in FIG. 13A contact valleys 224 a of the corrugations 228 a of the corrugated regions after the treated web is folded. As shown in FIG. 13B, side walls 262 a along with the flats of treated web define a cell 264 a having a cell interior 266 a after the treated web is folded and the skins applied to the upper and lower horizontal portions of the folded web.

FIGS. 13C and 13D illustrate an alternative extrusion 216 b. This extrusion 216 b, shown in cross-section in FIG. 13C, has a generally non-planar profile or non-linear, cross-section. In cross-section, the extruded web 216 b has a generally corrugated configuration or shape, including a plurality of peaks 222 b and a plurality of valleys 224 b joined together by connecting portions 226 b, all extending in the direction of travel of the web during the extrusion process. Each of the peaks 222 b, valleys 224 b and connecting portions 226 b are longitudinally extending, extending parallel the outer edges 220 b of the extruded web 216 b. The valleys 224 b are all generally co-planar in a horizontal plane P₁₇. Likewise, the peaks 222 b are all generally co-planar in a horizontal plane P₁₈ above the plane P₁₇. The linear distance between the planes P₁₇ and P₁₈ defines the height “HH_(b)” of the corrugations 228 b. At each peak 222 b and each valley 224 b, additional material is extruded so that each peak 222 b is generally rectangular in cross-section and has a flattened top 316. Similarly, each valley 224 b is generally rectangular in cross-section and has a flattened bottom 318. The additional material may cause the extrudate 216 b to be stronger than if the additional material were omitted.

FIG. 13D illustrates in cross-section a core 198 b made from the extrudate 216 b shown in FIG. 13C. As shown in FIG. 13D, after the extruded web 216 b is partially flattened and folded along fold lines, the connecting portions 226 b of the corrugations 228 b of the corrugated regions become side walls 262 b of the cells 264 b of the core 198 b. More particularly, the top surfaces 316 of peaks 226 b of the corrugations 228 b of the corrugated regions shown in FIG. 13D contact the flattened bottom surfaces of valleys 224 b of the corrugations 228 b of the corrugated regions after the treated web is folded. As shown in FIG. 13D, side walls 262 b, along with the flats of treated web, define a cell 264 b having a cell interior 266 b after the treated web is folded and the skins applied to the upper and lower horizontal portions of the folded web.

FIGS. 13E and 13F illustrate an alternative extrusion 216 c. This extrusion 216 c, shown in cross-section in FIG. 13D, has a generally non-planar profile or non-linear, cross-section. In cross-section, the extruded web 216 c has a generally corrugated configuration or shape, including a plurality of peaks 222 c and a plurality of valleys 224 c joined together by connecting portions 226 c, all extending in the direction of travel of the web during the extrusion process. Each of the peaks 222 c, valleys 224 c and connecting portions 226 c are longitudinally extending, extending parallel the outer edges 220 c of the extruded web 216 c. The valleys 224 c are all generally co-planar in a horizontal plane P₁₉. Likewise, the peaks 222 c are all generally co-planar in a horizontal plane P₂₀ above the plane P₁₉. The linear distance between the planes P₁₉ and P₂₀ defines the height “HH_(c)” of the corrugations 228 c. At each peak 222 c and each valley 224 c, additional material is extruded so that each peak 222 c is generally rectangular in cross-section and has a flattened top 320. Similarly, each valley 224 c is generally triangular in cross-section and has a flattened bottom 322. The additional material may cause the extrudate 216 c to be stronger than if the additional material were omitted.

FIG. 13F illustrates in cross-section a core 198 c made from the extrudate 216 c shown in FIG. 13E. As shown in FIG. 13F, after the extruded web 216 c is partially flattened and folded along fold lines, the connecting portions 226 c of the corrugations 228 c of the corrugated regions become side walls 262 c of the cells 264 c of the core 198 c. More particularly, the top surfaces 320 of peaks 226 c of the corrugations 228 c of the corrugated regions shown in FIG. 13E contact the flattened bottom surfaces 322 of valleys 224 c of the corrugations 228 c of the corrugated regions after the treated web is folded. As shown in FIG. 13F, side walls 262 c, along with the flats of treated web, define a cell 264 c having a cell interior 266 c after the treated web is folded and the skins applied to the upper and lower horizontal portions of the folded web.

FIGS. 13G and 13H illustrate an alternative extrusion 216 d. This extrusion 216 d, shown in cross-section in FIG. 13G, has a generally non-planar profile or non-linear cross-section. In cross-section, the extruded web 216 d has a generally corrugated configuration or shape, including a plurality of peaks 222 d and a plurality of valleys 224 d joined together by connecting portions 226 d, all extending in the direction of travel of the web during the extrusion process. Each of the peaks 222 d, valleys 224 d and connecting portions 226 d are longitudinally extending, extending parallel the outer edges 220 d of the extruded web 216 d. The valleys 224 d are all generally co-planar in a horizontal plane P₂₁. Likewise, the peaks 222 d are all generally co-planar in a horizontal plane P₂₂ above the plane P₂₁. The linear distance between the planes P₂₁ and P₂₂ defines the height “HH_(d)” of the corrugations 228 d. At each peak 222 d and each valley 224 d, additional material is extruded so that each peak 222 d has a recess 324. Similarly, each valley 224 d has a recess 326 which mates with or abuts the recess 324 of a peak 222 d when the extrudate is flattened and folded. The additional material and configuration of the peaks and valleys may cause the extrudate 216 d to be stronger than if the additional material were omitted.

FIG. 13H illustrates in cross-section a core 198 d made from the extrudate 216 d shown in FIG. 13G. As shown in FIG. 13H, after the extruded web 216 d is partially flattened and folded along fold lines, the connecting portions 226 d of the corrugations 228 d of the corrugated regions become side walls 262 d of the cells 264 d of the core 198 d. More particularly, the inner surfaces 328 of peaks 226 d of the corrugations 228 c of the corrugated regions shown in FIG. 13G contact mating inner surfaces 330 of valleys 224 d of the corrugations 228 d of the corrugated regions after the treated web is folded. As shown in FIG. 13H, side walls 262 d, along with the flats of treated web, define a cell 264 d having a cell interior 266 d after the treated web is folded and the skins applied to the upper and lower horizontal portions of the folded web.

FIGS. 26A-30 illustrate other methods or processes of making a multi-layered or sandwich-like product. FIG. 26A illustrates an extruded web 42″ like the one described above and shown in FIGS. 1B, 2B and 3B, traveling in a direction indicated by arrow 43. Using this process the extruded web 42″ is moved for a predetermined time period and then stopped while the extruded web 42″ is treated, i.e., material removed from the web. Once the treatment is temporarily completed, the extruded web 42″ is further moved. For example, an extruder may resume the extrusion process causing movement of the extruded web 42″ for another predetermined time period. However, any method of moving the extruded web 42″ may be used, such as a conveyor belt, for example. The extruded web 42″ may have a finite length or may be continuously produced upon demand. After being moved a predetermined distance, the extruded web 42″ is then stopped and treated. This process of intermittent movement and treatment of the extrusion may continue as long as desired and each stoppage time may be any desired programmed time.

The treatment step comprises removing generally rectangular-shaped portions or areas of the extruded web 42″ to create a treated or lightened web 336 having alternating treated and untreated generally rectangular areas 334, 342, respectively. This removal may include using movable tools 338, 340, such as shown in FIGS. 26A and 26B, to interrupt the continuous corrugations or flutes 136 of the extruded web 42″ and create a plurality of untreated, generally rectangular-shaped regions or blocks 342. As best shown in FIGS. 26A and 26B, the treated and untreated regions or areas 334, 342 alternate in the direction of travel 43 of the web.

Each treated and untreated region or area 334, 342, respectively, has a width defined as the linear distance between the side walls 132 of the extruded web 42″. As seen in FIGS. 26A and 26B, each untreated region or block 342 has a length “L” defined as the linear distance between the side edges 344 of the cut upper and lower walls 130, side walls 132 and spacers 134 cut during the removal step in the process. Each untreated region or block 342 has the same longitudinal length “L” which becomes the height of the middle core 370 of the sandwich-like product 332 after the folding step. The size and location of these untreated regions or blocks 342 may vary depending upon the desired size or shape of the cells 372 of the core 370 of the resultant sandwich-like product 332.

As seen in FIGS. 26A and 26B, each treated region or area 334 has a length “L1” defined as the linear distance between the side edges 344 of the cut upper or lower wall 130, side walls 132 and spacers 134 cut during the removal step in the process. Each treated region or area 334 has the same longitudinal length “L1” which, according to one embodiment, is twice the height “H2” of the extruded web 42″, as shown in FIG. 2B. The length “L1” of each of these treated regions or areas 334 is approximately twice the height “H2” of the extruded web 42″ in order to enable an operator or machine to fold the treated or lightened web 336, as shown in FIG. 29. After the folding step, the cut edges 344 of the extruded web 42″ contact or abut one of the upper or lower walls 130 of the extruded web 42″. The upper and lower walls 130 of the extruded web 42″ cover the cells 372 of the core 370. The cells 372 of the core 370 were the flutes 136 of the extruded web 42″ before the folding step shown in FIG. 29.

Each tool 338, 340 is illustrated as comprising a rotating dado blade. Although shown as being a particular size, each of these tools 338, 340 may comprise any known dado blade of any desired size or configuration or any other known rotating tool such as a milling tool. Although two tools are illustrated, any number of tools of any desired type or configuration may be used including a single tool. Again, the term tool is not intended to be limiting and may include any tool known in the art.

FIG. 26A illustrates dado blade 338 located on one side of the extruded web 42″ and the other dado blade 340 on the opposite side of the extruded web 42″. FIG. 26A illustrates dado blade 338 being above the extruded web 42″ and the other dado blade 340 being below the extruded web 42″. However, these may be reversed.

FIG. 26A illustrates the movement of the dado blades 338, 340 during one of the stops of the extruded web 42″, first dado blade 338 traveling in a first direction shown by arrow 348 perpendicular to the direction of travel 43 of the extruded web 42″, transversely or from side-to-side while rotating in the direction of arrow 345. The second dado blade 340 is illustrated in FIG. 26A traveling in a second direction shown by arrow 350 also perpendicular to the direction of travel 43 of the extruded web 42″ while rotating in the direction of arrow 347. After dado blades 338, 340 have each made their pass across the extruded web 42″, either simultaneously or one after the other, the extruded web 42″ is moved ahead a desired distance shown by the arrows 346 in FIG. 26B before the extruded web 42″ is stopped again for the next treatment step or material removal.

As shown in FIG. 26B, the rotating dado blades 338, 340 then pass across the stopped extruded web 42″ in directions opposite the directions they moved in the step shown in FIG. 26A while rotating. As shown in FIG. 26B, dado blade 338 moves from right to left in the direction of arrow 351 while rotating in the direction of arrow 353 and dado blade 340 moves from left to right in the direction of arrow 349 while rotating in the direction of arrow 355. After completing a cycle with two stops of the extruded web 42″, the dado blades 338, 340 are back in their original positions shown in FIG. 26A. Although the drawings show the dado blades in predetermined positions, it is within the contemplation of the present invention that the dado blades may start on opposite sides than those shown. For example, dado blade 338 may start on the left side of the stopped extruded web 42″ as shown in FIG. 26A and dado blade 340 start on the right side of the extruded web “42”.

As shown in FIGS. 27A and 27B, it is within the contemplation of the present invention that the dado blades 338, 340 travel in the same direction, as opposed to opposite directions while rotating and removing material from the web 42″. FIG. 27A illustrates dado blades 338, 340 located on the same side of the extruded web 42″ (on the left side of the extruded web 42″ as shown in FIG. 27A). Similarly, one of the dado blades, 338 is located above the extruded web 42″ and the other dado blade 340 is located below the extruded web 42″. However, these may be reversed. FIG. 27A illustrates the movement of the dado blades 338, 340 during one of the stops of the extruded web 42″, first dado blade 338 traveling in a first direction shown by arrow 352 perpendicular to the direction of travel 43 of the extruded web 42″, transversely or from side-to-side, while rotating in the direction of arrow 357. The second dado blade 340 is illustrated in FIG. 27A traveling in the same direction shown by arrow 352 perpendicular to the direction of travel 43 of the extruded web 42″ while rotating in the direction of arrow 357, same as dado blade 338. After rotating dado blades 338, 340 have each made their pass across the extruded web 42″, either simultaneously or one after the other, the extruded web 42″ is moved ahead a desired distance shown by the arrows 346 in FIG. 27B before the extruded web 42″ is stopped and treated again.

As shown in FIG. 27B, the dado blades 338, 340 then pass across the stopped extruded web 42″ in the opposite direction (from right to left across the extruded web 42″ as shown in FIG. 27B). As shown in FIG. 27B, dado blades 338, 340 move from right to left in the direction of arrows 354. After completing a cycle with two stops of the extruded web 42″, the dado blades 338, 340 are back in their original positions shown in FIG. 27A. Although the drawings show the dado blades in original positions, it is within the contemplation of the present invention that the dado blades may start on the opposite side (the right side as shown in FIG. 27A) rather than as shown in FIG. 27A.

As shown in FIGS. 26A and 26B, as the rotating dado blade 338 moves either from left to right in the direction of arrow 348 or from right to left in the direction of arrow 351 across the width of the extrudate 42″, the rotating dado blade 338 removes the upper wall 130, side walls 132 and spacers 134 from the extruded web 42″ without removing the lower wall 130. The outer edges 356 of the rotating dado blade 338 may leave grooves 358 or score lines (not shown) extending transversely from one side edge 360 of the lower wall 130 of the extruded web 42″ to the other side edge 360. Once the rotating dado blade 338 has completed its pass across the width of the extruded web 42″ it leaves a generally rectangular treated or lightened area 334 which has less mass than adjacent untreated generally rectangular regions or blocks 342.

As shown in FIGS. 26A and 26B, either simultaneously or at different times than movement of dado blade 338, rotating dado blade 340 moves from right to left in the direction of arrow 350 or from left to right in the direction of arrow 349 across the width of the extrudate 42″. During its movement, rotating dado blade 340 removes the lower wall 130, side walls 132 and spacers 134 from the extruded web 42″ without removing the upper wall 130. The outer edges 362 of the rotating dado blade 340 may leave grooves 358 or score lines (not shown) extending transversely from one side edge 364 of the upper wall 130 of the extruded web 42″ to the other side edge 364. In some applications, the dado blades or tools may not leave any grooves 358. Once the dado blade 340 has completed its pass across the width of the extruded web 42″ it leaves a generally rectangular treated or lightened area 334 which has less mass than adjacent untreated generally rectangular regions 342. Each of the untreated generally rectangular regions or blocks 342 is not contacted by either of the rotating tools and remains as it was extruded. The same is true when the rotating dado blades 338, 340 travel in the same direction, as shown in FIGS. 27A and 27B, for example.

As shown in FIG. 28, during the step of removing selected portions of the extruded web 42″, the tools 338, 340, or portions thereof, may be chilled, at ambient temperature, or heated by any desired method to facilitate processing. Similarly, extruded web 42″, or portions thereof, may be chilled, at ambient temperature, or heated by any desired method to facilitate removal of material. Such heating is illustrated schematically by arrows 366. This heating step is optional and may be used in certain applications only. In other applications, it may be omitted partially or entirely. Although it is shown schematically after the lightened areas or strips 334 have been created by the tools 338, 340 in the extruded web 42″, this heating step may occur any time during this manufacturing process.

As shown in FIGS. 28 and 29, the treated or lightened web 336 is then folded along transversely extending fold lines 368 located generally along the grooves 358 formed in the upper and lower walls 130 of the extrudate “42”. Such fold lines 368 may be optionally scored or perforated at any step in the manufacturing process with cuts (not shown) to assist folding. Such scoring may be made by a separate tool or tools. As shown in FIG. 28, after the treated or lightened web 336 is folded along transversely extending fold lines 368, upper and lower walls 130 of extrudate 42″ in the untreated portions of the extruded web 42″ only change their orientation approximately 90 degrees while the upper and lower walls 130 of extrudate 42″ in the treated portions of the extruded web 42″ remain in their original orientations. The flutes 136 of the extruded web 42″ become the cells 372 of the middle core 370 of resultant product 332 after folding. The untreated rectangular regions 342 of the extruded web “42” become blocks of the folded web 372, each block 342 being a height “L”, as shown in FIG. 29.

As shown in FIG. 29, removal of material by the tools 338, 340 between two adjacent untreated blocks 342 enables the folding of adjacent blocks together. As shown in FIG. 29, the block 342 a on the right of the drawing is folded in the direction of arrow 374 (clockwise), one of the cut edges 344 of the block 342 (along the left edge of block 342 a) moves towards the remaining upper wall 130 of the adjacent cut or treated portion 334 until the cut edge 344 of the block 342 a contacts the adjacent upper wall 130 to its left. Due to the height “H2” of the untreated block 342 being approximately half the distance of the length “L1” of the treated region, the cut edge 344 of the untreated block 342 a covers approximately half the surface area of the remaining upper wall 130 of the treated region 334.

Similarly, an upper portion of the next untreated block 342 b moves in the direction of arrow 376 (counterclockwise) such that one of the cut edges 344 of the block 342 b (along the right edge of block 342 b) moves upwardly towards the upper wall 130 of the treated region 334 immediately to its right. After the cut edge 344 of block 342 b contacts the uncovered half of the upper wall 130 of the treated region 334, the upper wall 130 of the treated region is fully supported by the two blocks 342 a, 342 b.

A lower portion of the next untreated block 342 c (third from the right in FIG. 29) moves in the direction of arrow 378 (clockwise) such that one of the cut edges 344 of the block 342 c (along the right edge of block 342 c) moves downwardly towards the lower wall 130 of the next treated region 334 immediately to its right. Due to the height “H2” of the untreated blocks 342 being approximately half the distance of the length “L1” of the treated region, the cut edge 344 of the untreated block 342 c covers approximately half the surface area of the remaining lower wall 130 of the treated region 334. The other cut edge 344 of the block 342 b (along the left edge of block 342 b) moves downwardly into contact or engagement with the lower wall 130, thereby covering the other half of the surface area of the lower wall 130. After the cut edge 344 of block 342 b contacts the uncovered half of the lower wall 130 of the treated region 334, the lower wall 130 of the treated region is fully covered by the two blocks 342 b, 342 c. As the folding step continues, the middle core 370 continues to increase in length.

As shown in FIG. 29, the treated 336 is folded alternatively in upper and lower planes to create a plurality of blocks 342, each block 342 containing a row of vertically oriented cells 372. If desired, adjacent blocks 342 may be adhesively or otherwise joined to each other to create product with or without skins 380.

FIG. 30 shows outer skins or layers 380 being applied to the upper and lower surfaces of the middle core 370 to create a multi-layered or sandwich-like web 382. If desired only one or no outer skins may be applied. Heat and/or adhesive may be used to apply the outer skins 380 to the middle core 370. Each of outer skins 380 is supplied by a roll 381 supported by a rotatable support 383.

FIG. 31 shows the multi-layered or sandwich-like web 382 being cut to a desired length by a cutter 385 placed at a desired location. The cutter 385 is designed to move transversely or perpendicular to the direction of movement of the multi-layered or sandwich-like web 382. FIGS. 31 and 32 illustrate one form of cutter 385. However, one or more cutting tools or devices may be used at any desired location to cut either the multi-layered or sandwich-like web 382 of FIG. 31 or the middle core 370 only as shown in FIG. 32. In either process, the result is a finished sandwich-like or multi-layered product 332 of a desired length. Although only two outer skins 380 are illustrated being applied to the middle core 370 before the cutting process in FIG. 31, more than two outer skins 380 may be applied.

FIG. 32 illustrates the cutter 385 cutting only the middle core 370 without any outer skins. After the middle core 370 has been cut two generally rectangular outer skins 390 are applied to the cut middle core 370 to create the finished sandwich-like or multi-layered product 332. Although only two outer skins 390 are illustrated being applied to the middle core 370 after the cutting process in FIG. 32, any number of outer skins including more than two outer skins 390 may be applied to the middle core 370.

While I have described several preferred embodiments of the present invention, persons skilled in the art will appreciate changes and modifications which may be made without departing from the spirit of the invention. For example, although one configuration of a cell is illustrated and described, the cells of the present invention may be other configurations, such as cylindrical in shape. Therefore, I intend to be limited only by the scope of the following claims and equivalents thereof. 

I claim:
 1. A process of making a sandwich-like product, said process comprising, in any desired order: providing an extruded web having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes; removing portions of the extruded web using multiple movable tools to create a treated web having lightened areas transversely extending from one side edge of the extruded web to the other side edge of the extruded web; folding the treated web such that upper and lower walls of the untreated regions of the treated web become sidewalls of a plurality of cells arranged in rows of a core of the sandwich-like product; applying outer skins to tops and bottoms of the cells of the core to create a multi-layered web.
 2. The process of claim 1 further comprising cutting the multi-layered web.
 3. The process of claim 1 wherein removing portions of the extruded web comprises using rotating tools.
 4. The process of claim 3 wherein the rotating tools comprise dado blades.
 5. The process of claim 3 wherein the rotating tools travel in opposite directions.
 6. The process of claim 3 wherein the rotating tools travel in the same direction.
 7. A process of making a sandwich-like product, said process comprising, in any desired order: moving an extruded web of material having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes; stopping the web and removing portions of the extruded web while the extruded web is stopped using at least one movable tool to create a lightened web; folding the lightened web such that the flutes of untreated regions of the lightened web become cells of a middle core; resuming movement of the web; applying outer skins to the tops and bottoms of the cells of the middle core to create a multi-layered web.
 8. The process of claim 7 further comprising cutting the multi-layered web.
 9. The process of claim 7 wherein removing portions of the extruded web while the extruded web is stopped comprising using multiple movable tools.
 10. The process of claim 7 wherein removing portions of the extruded web comprises using at least one rotating tool.
 11. The process of claim 10 wherein removing portions of the extruded web comprises using multiple dado blades.
 12. The process of claim 11 wherein the dado blades travel in opposite directions.
 13. The process of claim 11 wherein the dado blades travel in the same direction.
 14. The process of claim 7 wherein the extruded web is heated prior to removing portions of the extruded web.
 15. A process of making a sandwich-like product, said process comprising, in any desired order: removing rectangular-shaped portions from an extruded web to create alternating treated and untreated rectangular areas in a lightened web, the extruded web having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes; folding the lightened web such that untreated regions of the extruded web become blocks, each of the blocks comprising a plurality of cells arranged in a row; joining adjacent blocks to each other to create a create a middle core; applying outer skins to the middle core.
 16. The process of claim 15 wherein removing portions of the extruded web comprises removing portions of the extruded web while leaving at least one of the upper and lower walls of the extruded web remaining.
 17. The process of claim 15 wherein removing portions of the extruded web comprises using rotating tools.
 18. The process of claim 15 wherein the rotating tools comprise dado blades.
 19. The process of claim 17 wherein the dado blades travel in opposite directions.
 20. The process of claim 17 wherein the dado blades travel in the same direction. 